Wall construction



June 26, 1934.

E. W. LESHER WALL CONSTRUCTION Filed Aug. 6, 1929 3 Sheets-Sheet 2INVENTOR EARL WLESHER.

ju/mm ATTORNEY n a. a m m 6 m 2 WW m S L R 5 A A E 0 HM Pu S i 1. Y W G.I n I "4 mm lav: E m I 6 June 26, 1934.

' ATTORNEY Patented June 26, 1934 PATENT OFFICE WALL CONSTRUCTION EarlW. Lesher, Lakewood, Ohio Application August 6, 1929, Serial No. 383,799

13 Claims.

This invention relates to wall and ceiling constructions, moreparticularly to blocks, mats or sheets therefor adapted to serve assurfacing for walls or ceilings or as structural members or portionsthereof applied directly to studding, ceiling beams and like-elements;furthermore, when the blocks, mats or sheets'embodying my invention aremade of porous material, a large increase in surface area, per unit areaof wall surface, results, and on account of the sound absorbing ortrapping character of the material, such blocks,-

\ mats or sheets operate to absorb to a maximum extent sound or soundwaves, prevents reverberations and echo and improves to a marked extentthe acoustical properties of the room, auditorium and the like havingits walls formed therewith.

One object of the invention is to provide an improved block, mat orsheet capable of use as a wall or ceiling, or as surfacing therefor.

Another object of the invention is to provide improved wall or ceilingblocks, each so constructed that the area exposed to sound or soundwaves is increased several times as compared to the wall area covered bythe blocks.

' Another object of the invention is to provide improved blocks whichlend themselves for use for wall or ceiling constructions or as linersbetween the inner wall or sheathing and the external covering orsheathing of a building, where heat insulation or air circulation orboth are desired.

A further object of the invention is to provide an improved wall orceiling block that is (a) formed of a material capable of absorbingsound waves and (b) constructed to expose a relatively large area,whereby increased efilciency results.

Other objects of the invention will be apparent to those skilled in theart to which my invention relates, from the following description takenin connection with the accompanying drawings, wherein Fig. 1 is afragmentary view showing a room having its ceiling and side walls formedof blocks embodying my invention.

Fig. 2- is a fragmentary view of a wall or celling showing one of theblocks in position (somewhat enlarged) and portions of adjacent blocksspaced therefrom to illustrate the interlocking elements between theblocks and the manner in which they are positioned or assembled whenconstructing the wall.

Fig. 3 is a section on the line 3-3 of Fig. 2.

- Fig. 4 is .a side view of the parts shown in Fig. 2.

Fig. 5 is a fragmentary view of a plurality of base members in relatedposition to illustrate the manner in which the blocks are assembled; thesurface members of the blocks being omitted.

Fig. 6 is a rear view of certain of the parts shown in Fig. 5.

Fig. '7 is a fragmentary section on the line 7-7 of Fig. 5.

Fig. 8 is a perspective view of a portion of one of the surface members.

Fig. 9 is a perspective view of a portion of one of the surface membersembodying a modified form of construction.

- Fig. 10 is a fragmentary view of a base member embodying a modifiedform of .construction.

Fig. 11 is a fragmentary view, similar to Fig. 2, but showing a blockhaving a base member constructed as shown in Fig. 10.

Fig. 12 is a fragmentary view similar to Fig. 2, but embodying anothermodified form of construction.

Figs. 13 and 14 are fragmentary views illustrating the process of makingthe surface members.

In the use of the term wall or walls herein it is understood tocomprehend the side walls and ceilings of rooms,,auditoriums and hallsor DOr- 8 tions thereof, and in the use of the term blocks it isunderstood to refer to wall and ceiling units of any desired size,whether the same are used for and constitute the walls or ceiling of aroom and the like or are used as surfacing for walls and ceilings, sincethe same may be applied to or upon the surfaces thereof for decorativepurposes and acoustical purposes, either or both.

In some instances blocks embodying my invention may be used as above setforth for decorative purposes, in which event they may be made of anydesired material, but by preference, such blocks are constructed ofsuitable sound absorbing material and on account of their improvedstructural y characteristics they are peculiarly adapted for the wallsand ceilings of rooms and the like where perfect acoustic conditions aredesired. For the latter reason, I prefer to form the blocks embodying myinvention from a fibrous material, such as "Celotex" boards or sheets0011: sisting of a felted mass of bagasse fibers or "Insulite boards orsheets formed from wood pulp. These and similar fibrous materials arerelatively light in weight and so compacted in their manufactured formthat they may be readily cut, 1 sawed, drilled or gouged 'and alsonailed.

Furthermore, their surfaces may be readily coated, when desired, withpaint and other surfacing materlals. 7

As is well known, boards or sheets made from 11 these materials have,throughout their mass, numerous air cells or interstices, which arecapable of receiving sound waves, so that by gouging out portions ofsuch boards according to my process I am enabled to expose to the soundwaves a multiplicity of surfaces, per unit of area, upon or over whichthe walls of the cells or interstices have been broken down to the endthat the sound waves may freely ehter these cells and interstices andpenetrate into and throughout the remaining mass of material.

In the manufacture of these materials into commercial form, they aremade from wet pulp and squeezed or pressed into boards or sheets. As aresult of this process, a. film or skin is formed on their oppositefaces so that the cells or interstices thereon are substantially closed,but in my form of construction and in carrying out my process arelatively small amount of these surfaces are utilized; on the otherhand a relatively large area of the interior mass of these boards isexposed to the sound waves so that maximum absorption thereof results.

In the drawings, 1 indicates studding or uprights mounted on suitableflooring 2 or on beams 3 and connected at their upper ends by ahorizontal member 4. The studding may be braced by cross members ordiagonals (not shown). 5 indicates ceiling rafters carried by thehorizontal member 4. 6 indicates a sheathing forming part of theexternal wall of the structure. The parts described illustrate oneexample of the structural elements forming a wall and ceilingconstruction. 7 indicates the side wall and 8 indicates the ceiling,each made up of blocks 8' embodying my invention and showing theirapplication to or mounting directly upon the studding 1 and rafters 5.Where the wall and ceiling are complete, that is covered with plaster,beaver boards, Celotex boards, Insulite boards, wooden sheathing, sheetmetal or other form of wall and ceiling construction, my blocks may beapplied thereto with equal facility.

Each block 8' consists of a composite unit or section comprising a basemember 9 and a surface member 10, each formed from fibrous material,such as above described, and having a length equal to the distancebetween centers of adjoining studding 1 and rafters 5. The base member 9shown in Figs. 2, 3, 4, 5 and 6, consists of a basal portion 9a and aplurality of spaced strips 11, preferably disposed in'parallel relationand extending from end to end of the basal portion, to form sound wavereceiving or circulating channels 11, the bottom 12 and sides 12a ofeach of which provide exposed sound wave absorbing areas or surfaces.The strips 11 are preferably integrally connected with the basal portion9a. The first step of my process consists in forming the base member 9.In carrying out this step, a board of fibrous material is fed relativeto a plurality of spaced cutters or gouging devices (such as shown at A,Fig. 13) which remove or cut out the material from the board and formthe channels 11. While the fibrous material herein referred to may bemolded to any desired shape, I prefer to gouge ,out the material sincein this latter method the surfaces of the channels are not covered witha film or skin, which, in molding would result from contact with themold walls, but are left or finished in a more or less rough state withthe inherent air cells and interstices on these surfaces open.

Each surface member 10 comprises a plurality of superposed layers ofspaced elements 13, 14,

'angles to each other.

those elements of one layer extending at an angle to those of the otherlayer, preferably at right angles, with the inner layer 13 extending atany angle, preferably at right angles, to the strips 11. As shown, thespaced elements 13 extend continuously from one side edge to theopposite side edge of the member; whereas the elements 14 are preferablycut away transversely, as will later appear. In this arrangement, (a)the side walls 13a of the elements 13, (b) the bottom or inner Walls 14aof the elements 14 between the side walls 13a, (0) the upper surfaces13b of the elements 13 between the elements 14, forming channels 141v,(d) the side walls 14b of the elements 14 and (e) the edge portions 130of the elements 13 along the lateral sides of the base member formexposed sound wave absorbing areas or surfaces. Also, by preference, theelements 14, instead of being continuous from edge to edge of themember, are cut away along transverse lines midway between the sidewalls 13a to form transverse channels 16, the side walls 16a. and bottomwalls 16b of which provide additional or auxiliary sound wave absorbingareas or surfaces.

In addition to the areas already referred to, the outer faces of theelements 14 form sound Wave absorbing areas.

By reason of the spaces or channels 14:1: between the elements 14, whichchannels extend at an angle to the channels (designated 13$) between theelements 13, sound waves pass into the latter channels; and as thesechannels 13:: extend at an angle to the channels 11', the sound wavesare free to pass into these latter channels. As the channels 13:: and 11extend from end to end of the block, the sound waves may circulatefreely therethrough while being absorbed.

In the construction above described, certain of the areas are in opposedrelation one to another and certain other of the areas are at right Inthis arrangement, the waves in passing through the openings between theelements 14 to the channels 13: between the elements 13 and to thechannels 11' impact against and are deflected from one wall or area toanother, so that their energy is taken up by such impact and deflection.

In my construction the inlet spaces leading to the channels 132: and 11'are relatively small so that danger of the waves emerging from thechannels is greatly reduced.

In some instances I may modify the form of construction by omitting thesound absorbing.

absorbing areas I may cut additional material out of the elements 14,preferably along lines 18, 18, as shown in Fig. 9, forming channels 18abetween the resulting elements 14'. In this form of construction theside walls 140 of the elements 14' and the increase in exposed areas ofthe strips 13, as shown at 14d, provide auxiliary wave absorbing areas.

In Fig. 9 I have shown but one channel 180 in each element 14, but itwill be understood that additional channels may be provided whereincrease wave absorbing areas are deemed desirable. Increased sound waveabsorbing areas may also be provided by cutting away those portions ofthe strips 11 disposed between the elements 13, as shown at 19 in Fig.12, the sides 19a of the resulting lands or portions 19' serving assupplemental wave absorbing areas; and the lands 19' serving to supportthe elements 13, being secured thereto as hereinafter set forth.

When desired, surface members such as shown in Fig. 9 may be assembledwith base members of the construction shown in Fig. 12 to form compositeblocks.

In forming the base member of the form shown 1 in Fig. 12, the board maybe fed relative to a cutting or trimming series of cutters as alreadydescribed to form the channels 11 and then turned and fed relative tothe cutters to cut away spaced portions of the strips.

To construct the surface members 10, I provide a machine (see Fig. 13)having two sets of cutters A, B, on parallel shafts A, B, with thecutters in alternate arrangement and the shafts so spaced that theperipheries of the cutters extend to or intersect a plane disposedmidway between the opposite sides or faces of the boards to be cut andshaped. In this machine, a portion only ofwhich is shown, the sets ofcutters extend from edge to edge of the board and the outer cutters B ofthe upper set are provided with knives C which sever the section andtrim its side edges. By preference, the cutters Aare relatively wide toprovide wide channels between the elements 13. The next step in myprocess consists in feeding the board stock relative of the cutters A,B, such operation being shown in Fig. 13. In carrying out this step ofmy process, the channels 13.1: are formed in one face of the board stockand channels 14:: are formed in the other face thereof. Next, I turn theboard stock a distance of 90 and feed it relative to a set of cutterssuch as the set Bx (Fig. 14) bringing that face of the board having thechannels 141: into engagement with the cutters; this operation formingthe channels 16 and the knives C on the outer cutters serving to trimthe side edges of the section. In carrying out this step the cuttersand-the supporting surface for the stock are so spaced that the cutterscut through that portion of the stock above the channels 133:, that is,these outters intersect the channels 132:, openings therein.

In carrying out these last described steps, the cutters and the knivesC, C are so arranged that the board stock will be cut into sections ofthe desired length and width, thereby making it unnecessary to subjectthe stock to an additional operation; furthermore, both operationsareeffected upon the same portion of the stock so that the resultingspaced elements 13, 14, are integral. When the surface member 10 is tobe formed with channels 18a, it is fed to a set of cutters similar tothe cutters B in the desired spaced relation.

Next, the base member 9 and surface member 10 are assembled and securedtogether, to form a composite block -8. To secure the members together Iuse a suitable glue or paste, coating the same on those portions of thestrips 11 and elements 13 that contact face to'face and if desiredpressure may be applied to the members to insure their adhesion.

In addition to the steps already described I may perform an auxiliary informing or shaping it.

In forming and shaping the base member 9 I provide it along its sideedges with complementary interlocking elements 20, these elements so asto provide.

step on each member being provided by subjecting each side edge to aseries of cutters of the'desired shape in cross section. The elements 20on each side edge consist of alternately arranged projections 21 andrecesses 22, each projection 21 on one side edge being aligned with arecess on the opposite side edge, so that when two members are relatedthe projections 21 on one member interlock with the recesses in theother member. As shown, each of the elements 21, 22, has a beveled face23 extending outwardly and inwardly, respectively, relative tocorresponding end edges 24 on all of the side edges of the member; suchbevel faces extending from the face of the member adjacent to or whichterminates along the edges 24 to the opposite face of the member. Bysuch arrangement the base members 9 are of uniform construction andinterchangeable, and thus permit either longitudinal side edge to becomethe upper or lower side edge in"positioning it, and where the compositeblocks 8' are of rectangular shape, and where they are of square shape,as shown, they may be positioned without respect to any particular sideedge. By preference, the sides of "the projections 21 diverge and thesides of the recesses 22 converge relative to the edges 24 and the outerwall of that recess on each side edge which terminates at one end ofsuch edge, is cut away as shown at 26, this form of constructionpermitting the blocks, after the first row is assembled, to beassembled, row after row, each block being moved into final position inthe direction of the arrow :2: (Fig. 5) and providing an interlockingjoint on all sides of each block, with the result that there is auniform thickness of material over the entire wall area and the jointsbetween the blocks are substantially closed. This interlocking joint hasan additional advantage where the blqcks are secured to spaced studding1 or rafters 5, as shown in Figs. 1, 2, 3, 4, 11 and 12. In this form ofconstruction the blocks are unsupported between the structural elements1 and 5. By interlocking the side edges of the blocks together (that is,those side edges which extend at right angles to the studding andrafters), I prevent warping or sagging of the sections one relative toanother. This form of joint construction is also advantageous where thebase members 9 are to be used as sheathing units or plaster boarding,since the joint between the members on their outer faces is on astraight line along the edge 24, and the adjacent marginal portions ofthe members may be cut away ,as shown at 27 (Figs. 7 and 10) to form akeying groove. However, when the base members are to be used for thispurpose, the beveled faces start from a line 26a, which is the inneredge of the cut-away 27.

In forming the surface member 10, end cutand sides of the elements 13 adistance equal to one-half the width of the spaces or channels betweenthem. As a result of this construction, when the blocks 8' areassembled, the ends and sides'of the elements 13 abut and position therelated elements 14 on adjoining blocks in the same spaced relation asthe elements 14 occupyv on each block. 'Accordingly,-when the blocks 8are assembled or laid, as shown in Fig. 1, the wall is uniform inconstruction and appearance throughout.

In laying the blocks, it is only necessary to nail the projections 21along one side edge, to the studding 1, as shown at 28, since theinterlocking elements between it and the side edge of the next block tobe engaged therewith will secure the latter to the studding.

From the foregoing description it will be apparent that my improvedblock increases to a substantial extent the area that is exposed to thewaves. For example, it may be assumed that the block 8 shown in Fig. 2is 16 inches square, thus covering a wall area of 256 square inches. Inthe form of construction shown in this view, each channel 11' has adepth of 4 inch and a width of inch and there are eleven channels ineach base member; accordingly the areas l2 12a,-12a, of these channelshave a total area of 198 square inches. The elements 13 are 4 inch thickand the spaces between them have a width of inch and the elements 14 are1% inches square; accordingly the areas l3a-l4a have a total area of 208square inches. The elements 14 are inch thick and are spaced inch; andthe elements 13 are inch wide; accordingly the areas 13b14a andl6a16a-l6b, have a total area of 217% square inches. The ele-- ments 14are 1 inches square and have a surface area of 225 square inches. Thesecombined areas when added together give a total exposed area of 848%square inches for each block.

To those skilled in the art to which my invention relates, many changesin construction and widely differing embodiments and applications of theinvention will suggest themselves without departing from the spirit andscope thereof. My disclosures and the description herein are purelyillustrative and are not intended to be in any sense limiting.

What I claim is:

1. A combined acoustic and surfacing block formed of fibrous materialfor walls of rooms and the like having parallel channels formed in itsopposite faces, those on one face being disposed at an angle to those onthe other face, and

each channel on one face intersecting or merg ing at its inner portioninto the channel on the other face.

2. A wall member formed of fibrous material for walls of rooms and thelike having a series of parallel channels formed in its rear face, aseries of parallel channels formed in its front face, each parallel toand disposed in a plane intermediate the planes of adjoining channels inthe rear face, and a series of channels formed in the front faceextending at an angle to the other channels formed in said face andintersecting or merging into the channels on the rear face.

3. A composite wall surfacing block formed of fibrous material for roomsand the like comprising a basal member having a plurality of spacedstrips extending from one side edge of the block to the other side edgethereof and forming channels between them and a plurality of layers ofspaced elements in superposed relation on said strips, the spacedelements of each layer extending at an angle to the spaced elements ofthe next adjoining layer, the spaces between the elements of each layermerging into the spaces between the elements of the next adjoining layerof elements.

4. A block for walls formed from fibrous material and comprising a basemember provided with a plurality of spaced strips extending in parallelrelation from one side edge to the opposite side edge and formingchannels between them, and a surface member consisting of a plurality ofinner spaced elements supported on said strips and extending at rightangles thereto from one remaining side edge to the side edge oppositethereto and a plurality of outer spaced elements resting on the firstmentioned spaced elements and bridging the spaces between them.

5. A block for walls formed from fibrous material and comprising a basemember provided with a plurality of spaced strips extending in ,parallelrelation from one side edge to the opposite side edge and formingchannels between them, and a surface member consisting of a plurality ofinner spaced elements supported on said strips and extending at rightangles thereto from one remaining side edge to the side edge oppositethereto and a plurality of outer spaced elements resting on the firstmentioned spaced elements and bridging the spaces between them, the lastmentioned spaced elements being formed with a series of channels aboveand extending longitudinally of said first mentioned spaced elements.

6. A block for walls formed from fibrous material and comprising a basemember provided with a plurality of spaced strips extending in parallelrelation from one side edge to the opposite side edge and formingchannels between them, and a surface member consisting of a plurality ofinner spaced elements supported on said strips and extending at rightangles thereto from one remaining side edge to the side edge oppositethereto and a plurality of outer spaced elements resting on the firstmentioned spaced elements and bridging the spaces between them, the lastmentioned spaced elements being formed with series of channels, oneseries extending longitudinally of said first mentioned spaced elementsand the other series extending at right angles thereto and merging withthe spaces between them.

7. A block as claimed in claim 4 in which the spaced strips are cut awaythroughout their portions between the inner spaced elements.

8. A composite wall block comprising a base member provided with aseries of channels extending from side edge to side edge thereof, thebottoms and sides of the channels forming sound wave absorbing areas,and a surface member having a plurality of parallel elements extendingat right angles to said channels and supported on those portions of saidbase member between the channels and a plurality of elements eachsupported on adjoining parallel elements and bridging the space betweenthem, the last side elements being in spaced relation one to another,the side walls of said parallel elements and under surfaces of the lastmentioned elements forming sound wave absorbing areas.

9. A unitary wall block formed of fibrous material for rooms and thelike comprising a basal member and a member superposed thereon andhaving parallel channels formed in its opposite faces, those on one facebeing disposed at an angle to those on its other face and each channelon one face intersecting or merging at its inner portion into thechannel on the other face.

10. An acoustic covering for a wall or the like comprising a panelmember having on its exposed surface a plurality of grooves and havingon its undersurface a plurality of grooves crossing the firstmentionedgrooves with said grooves cutting into each other where theycross to form apertures.

parallel grooves on its under surface extending at right angles to thegrooves on the outer surface, said grooves having a depth so as to cutinto each other at the points of crossing so as to form apertures.

13. A tile or the like fon covering a wall or the like for acousticpurposes comprising 'a fiber board inner member, spacer strips on theouter surface thereof, a fiber board outer member over the spacer stripswith said members and spacer strips forming a chamber, said outer fiberboard member having a multiplicity of grooves on its outer surface and amultiplicity of grooves on its inner surface extending in a directionwhereby to cross the grooves on its outer surface, said grooves havingsuch respective depth as to cut into each other at the points ofcrossing to form apertures through the outer fiber board whichcommunicates into said chamber.

E. w. manna.

